2005 sportsman 700 efi

The brake lever travels about an inch before full locking up the brake, feels solid. At about 1/2 inch is when slight braking starts. Pads are pretty worn. This all seem normal or should braking start immediately when pulling on the lever?

 

Worn pads just push the caliper pistons out to far.Pistons can stick and cause brake lever problems. Check for any caliper seal leaking,replace seal kits if needed, replace the pads,bleed the system and see how it does.

 

I'm not saying there are any problems, I'm stopping, just bled the system, just wondering what's normal. I checked there are no leaks, bone dry. I'll get pads but is 1 inch of travel bad or broken or a sign that there could be air in the system or just need new pads?

 

Space behind the caliper pistons is already filled with fluid when pads are extremely worn,pistons are usually extended out.The pads are probably right off the disc and you wont have to pull the lever that much to engage them.Replace the pads before it goes too far,bleed the system and hopefully that's all there is to it.

 

If I read OPT correctly he wants you to replace the pads before they get any lower. If the pads get to thin they can peel of the backing plate and damage the rotor for even more expense. Always better to replace disc pads when they are worn down, NOT worn out!

 

Yep,another way of saying what I meant..